Automotive Engineering: Powertrain, Chassis System and Vehicle Body

835 Pages·2009·50.82 MB·English

by  David Crolla

Automotive Engineering
Note from the Publisher
This book has been compiled using extracts from the The extracts have been taken directly from the above
following books within the range of Automotive source books, with some small editorial changes. These
Engineeringbooks in theElseviercollection: changes have entailed the re-numbering of Sections and
Figures.Inviewofthebreadthofcontentandstyleofthe
Blundell,MandHarty,D.(2004)TheMultibodySystems
source books, there is some overlap and repetition of
ApproachtoVehicleDynamics,9780750651127
material between chapters and significant differences in
Brown,J.,Robertson,A.J.andSerpento,S.(2001)Motor
style,butthesefeatureshavebeenleftinordertoretain
Vehicle Structures,9780750651349
the flavourand readability of theindividual chapters.
Davies, G. (2003) Materials for Automobile Bodies,
9780750656924 Unitsofmeasure
Fenton,J.andHodkinson,R.(2001)LightweightElectric/ Units are provided in either SI or IP units. Aconversion
Hybrid VehicleDesign,9780750650922 table for these units is provided at the front of the
Garrett, T.K., Newton, K. and Steels, W. (2000) The book.
Motor Vehicle 13e,9780750644495
Happian-Smith,J(2001)IntroductiontoModernVehicle Upgrade to anElectronic Version
Design, 9780750661294 An electronic version of Automotive Engineering, the
Heisler, H. (1998) Vehicle and Engine Technology, AutomotiveEngineeringe-MegaReference,9781856175784
9780340691861
(cid:2) Afullysearchable Mega ReferenceeBook, providing all
Martyr, A.J. and Plint, M.A. (2007) Engine Testing 3e,
theessentialmaterialneededbyAutomotiveEngineers
9780750684392
onaday-to-daybasis.
Pacejka, H. (2005) Tyre and Vehicle Dynamics,
(cid:2) Fundamentals,keytechniques,engineeringbest
9780750669184
practiceandrules-of-thumbatonequickclickof
Reimpell, J., Stoll, H. and Betzler, J. (2001) Automotive
abutton
Chassis:EngineeringPrinciples,9780750650540
(cid:2) Over 1,500 pages of reference material, including over
Ribbens, W. (2003) Understanding Automotive Electron-
1,000pagesnotincludedintheprintedition
ics,9780750675994
Vlacic, L. and Parent, M. (2001) Intelligent Vehicle Tech- Go to http://www.elsevierdirect.com/9781856175777
nologies,9780750650939 and click on Ebook Available
Automotive
Engineering
Powertrain, Chassis System and Vehicle Body
Edited by David A. Crolla
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Contents
Section1 INTRODUCTIONTOENGINEDESIGN ................................................ 1
1.1 Piston-engines cycles of operation .. .... .... ..... .... .... .... ..... .... .... .... .3
Section2 ENGINETESTING .............................................................. 19
2.1 Measurementoftorque,power,speed and fuel consumption; acceptance
and type tests, accuracyof themeasurements . ..... .... .... .... ..... .... .... ....21
Section3 ENGINEEMISSIONS ............................................................ 51
3.1 Emissions control ... .... ..... .... .... .... ..... .... .... .... ..... .... .... ....53
Section4 DIGITALENGINECONTROL ...................................................... 75
4.1 Digital engine controlsystems .. .... .... .... ..... .... .... .... ..... .... .... ....77
Section5 TRANSMISSIONS ............................................................. 105
5.1 Transmissions and driveline .... .... .... .... ..... .... .... .... ..... .... .... ...107
Section6 ELECTRICVEHICLES .......................................................... 141
6.1 Battery/fuel-cell EV design packages .... .... ..... .... .... .... ..... .... .... ...143
Section7 HYBRIDVEHICLES ............................................................ 173
7.1 Hybrid vehicle design .... ..... .... .... .... ..... .... .... .... ..... .... .... ...175
Section8 SUSPENSIONS ............................................................... 203
8.1 Typesofsuspension and drive . .... .... .... ..... .... .... .... ..... .... .... ...205
Section9 STEERING .................................................................. 255
9.1 Steering .. .... .... .... ..... .... .... .... ..... .... .... .... ..... .... .... ...257
Section10 TYRES ..................................................................... 283
10.1 Tyres and wheels ... .... ..... .... .... .... ..... .... .... .... ..... .... .... ...285
Section11 HANDLING .................................................................. 323
11.1 Tyre characteristics and vehicle handling and stability .... .... .... ..... .... .... ...325
Section12 BRAKES .................................................................... 359
12.1 Braking systems ... .... ..... .... .... .... ..... .... .... .... ..... .... .... ...361
v
CONTENTS
Section13 VEHICLECONTROLSYSTEMS ................................................... 391
13.1 Vehiclemotion control . .... .... .... ..... .... .... .... ..... .... .... .... ..... .393
Section14 INTELLIGENTTRANSPORTSYSTEMS ............................................. 417
14.1 Global positioning technology ... .... ..... .... .... .... ..... .... .... .... ..... .419
14.2 Decisional architecture. .... .... .... ..... .... .... .... ..... .... .... .... ..... .437
Section15 VEHICLEMODELLING ......................................................... 473
15.1 Modelling and assembly ofthe full vehicle .. .... .... .... ..... .... .... .... ..... .475
Section16 STRUCTURALDESIGN ......................................................... 525
16.1 Terminology and overview of vehicle structure types .. .... ..... .... .... .... ..... .527
16.2 Standardsedan (saloon) –baseline load paths ... .... .... ..... .... .... .... ..... .542
Section17 VEHICLESAFETY ............................................................. 567
17.1 Vehiclesafety ... ..... .... .... .... ..... .... .... .... ..... .... .... .... ..... .569
Section18 MATERIALS ................................................................. 591
18.1 Design andmaterial utilization ... .... ..... .... .... .... ..... .... .... .... ..... .593
18.2 Materialsfor consideration and use inautomotive body structures .... .... .... ..... .632
Section19 AERODYNAMICS ............................................................. 661
19.1 Body design: aerodynamics . .... .... ..... .... .... .... ..... .... .... .... ..... .663
Section20 REFINEMENT ................................................................ 673
20.1 Vehiclerefinement:purpose and targets .... .... .... .... ..... .... .... .... ..... .675
Section21 INTERIORNOISE ............................................................. 685
21.1 Interior noise:assessment and control ..... .... .... .... ..... .... .... .... ..... .687
Section22 EXTERIORNOISE ............................................................. 737
22.1 Exteriornoise:assessment and control ..... .... .... .... ..... .... .... .... ..... .739
Section23 INSTRUMENTATIONANDTELEMATICS ............................................ 783
23.1 Automotive instrumentation and telematics .. .... .... .... ..... .... .... .... ..... .785
Index........................................................................... 809
vi
Section One Section One Section One Section One Section One
Section One
Introduction to engine design
1
This page is left intentionally left blank
1.1
Chapter 1.1
Piston-engine cycles
of operation
Heinz Heisler
1.1.1 The internal-combustion
engine
The piston engine is known as an internal-combustion
heat-engine. The concept of the piston engine is that
asupplyofair-and-fuelmixtureisfedtotheinsideofthe
cylinder where it is compressed and then burnt. This
internal combustion releases heat energy which is then
converted into useful mechanical work as the high gas
pressures generated force the piston to move along its
stroke in the cylinder. It can be said, therefore, that
a heat-engine ismerelyanenergytransformer.
To enable the piston movement to be harnessed, the
driving thrust on the piston is transmitted by means of
a connecting-rod to a crankshaft whose function is to
convert the linear piston motion in the cylinder to
a rotary crankshaft movement (Fig. 1.1-1). The piston
canthusbemadetorepeatitsmovementtoandfro,due
to the constraints of the crankshaft crankpin’s circular
path and theguiding cylinder.
The backward-and-forward displacement of the Fig.1.1-1 Pictorialviewofthebasicengine.
pistonisgenerallyreferredtoasthereciprocatingmotion
of the piston, so these power units are also known as
reciprocating engines.
harness the working gases. It also provides a jacket to
contain a liquid coolant.
1.1.1.1 Engine components and terms Cylinder head This casting encloses the combus-
tion end of the cylinder block and houses both the inlet
The main problem in understanding the construction of and exhaust poppet-valves and their ports to admit air–
the reciprocating piston engine is being able to identify fuel mixtureand to exhaust thecombustion products.
andnamethevariouspartsmakingupthepowerunit.To Crankcase Thisisacastrigidstructurewhichsup-
this end, the following briefly describes the major portsandhousesthecrankshaftandbearings.Itisusually
components and the names given to them (Figs. 1.1-1 castasamono-constructionwiththecylinderblock.
and 1.1-2). Sump This is a pressed-steel or cast-aluminium-
Cylinder block This is a cast structure with cylin- alloy container which encloses the bottom of the crank-
dricalholesboredtoguideandsupportthepistonsandto case and providesa reservoirforthe engine’s lubricant.
VehicleandEngineTechnology,ISBN:9780340691861
Copyright(cid:2)1998HeinzHeisler.Allrightsofreproduction,inanyform,reserved.